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Plastic Part Design

Steven cheng
TOPWORKS PLASTIC MOLD

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A reasonable and optimal molded part

structure design can not only simplify plastic
injection mold manufacture, reduce the cost
of the mold, but also to simplify its molding
process to improve the good quality rate of
products.
Before the design of plastic parts, a designer
should learn about the function,
environmental conditions and loading
conditions （including dynamic and static
load), understand relations between
different parts and the effect of the
assembly. Plastic parts function should be It should be noted that materials with poor
accurate and as detailed as possible, the elongation qualities are highly susceptible to
more comprehensive the plastic parts cracking under external and internal forces-
design are, the better the design of the for instance, a boss where a screen expands
plastic parts can meet the requirements. its outer diameter during assembly.
It is also necessary to specify radii on
⚫ Radii exterior corners of certain parts where a
There are two main causes of plastic part square-cornered shaft will need to fit into a
failure: molded-in notches, and sharp plastic part. Examples of these parts include
internal corners. These are largely caused by pulleys and gears. Putting radii on external
designers failing to provide the part with a corners has many benefits, from sink and
sufficient internal radius to avoid the issue. stress reduction, to assisting with the
When radii are noted on drawings, they are material glow. Put simply, the larger the
often inadequately small, and their radius, the more impact load that section
importance in high-stress areas is neglected. will be able to absorb.

In reality, inner corners require a carefully

specified radius, to help cut down on stress
concentrations at these essential areas. If the
corner is too sharp, then the force factors at
this point can be tripled or even quadrupled.
For that reason, it is recommended that a
fillet or radius of 0.5-0.6 times the wall
thickness is incorporated at these points.
Such parts will allow one to reduce stress on
radiused corners compared to sharp,
nonradiused sections.
For instance, some designs will require a
sharp, 90-degree corner. If the part is
subjected to impact, then radii are essential
to absorb the energy at the corners, and
reinforce the ribs of the part. However, radii

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can have a negative impact on the
appearance of parts, as well as their ease of
packaging. If the radii become too big for
these factors, then the designer may wish to
solve the problem by opting for an impact-
modified material in the manufacturing
process.
Under test conditions, when the radius is
increased, parts are able to absorb more
energy before failing, and in many cases,
failure is averted entirely. Impact tests to
external corners show that energy
absorption can be increased up to five times
by incorporating larger, more rounded
corners- and at the top of the part, this
increase can be as much as ten times. On
the other hand, if ribs are added to make the
part stiffer, they can have a negative impact
on the part’s ability to absorb energy, since
the walls cannot deflect.
If the rib section is properly designed,
though, and an impact-modified resin is
used, then even a part which was otherwise
problematic may work well in practice. For
instance, polycarbonate is extremely good
at absorbing energy, and when coupled with
a larger radius, means the part will be able
to absorb a lot more energy before failing.
To gain a better understanding of why
thermoplastic materials behave the way they
do, and why some are naturally stronger
than others, it is necessary to understand
how they behave under standardized ASTM
testing of physical properties. All plastics
demonstrate a similar stress/strain curve,
where the failure occurs at or close to the
top of the curve (although this will vary
depending on filler and reinforcements).
Filled or reinforced resins come with a lower
elongation- some 10% or under- meaning
they are less able to absorb or deflect
energy upon impact. This means they need
a larger radius to cut down stress
concentrations when they are faced with
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loads or impacts.
In the case of short or long glass-reinforced
resins，this rule often comes under question
when datasheet values are examined. In
these cases, the data would seem to suggest
that more highly reinforced resins have an
increased impact value. In truth, though, this
is down to the effect of the glass fiber/resin
matrix strength at the notch; it does not
reflect the absorbing value of the base resin
itself. With a higher glass loading, a greater
radius is needed to make the part tougher.
⚫ Nonuniform Part Thickness
After insufficient radii, the next leading
cause of plastic part failure is nonuniform
wall thickness. This can cause wider
tolerances, warpage, voids and sinks, a poor
fill due to pressure drops, and stresses which
are molded-in. All of these issues are down
to bad part design, which stops the resin
from being able to pack out during the
molding process fully. If uniform sections are
used, then these can all be avoided.
Molded-in part stresses are often caused by
a combination of thick and thin sections.
When the part cools, this leads to different
shrinkages. Since the thicker section holds
more heat, this can lead to all manner of
issues such as sinks, voids, and warpage.
It can also lead to flow problems around
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corners since it encourages pressure drops
and dead pressure flow areas. If nonuniform
section thickness is used, and thin part
sections feed thicker sections, the pressure
will drop in the thicker section. That may
mean that the part is not sufficiently filled.
On top of this, the thin section could
become over-packed when trying to fill the
thicker section.
Designers will, therefore, need to transition
and core out thick sections, to make the part
thickness as uniform as it can be. Not only
does this reduce these internal sinks and
voids, but it also makes the part stronger,
and saves on wasted materials.
better designs. Multiple smaller ribs, or a
single large yet thin rib, are more effective
than one large, thick rib. This can be
demonstrated by calculating the stiffening
effects of each option. In the case of thinner
rib sections, molding and part problems are
cut, and the part gains additional impact
resistance because molded-in stresses in
these areas are lowered.

Designers should, therefore, use the

moment of inertia calculations to come up
with a rib design that reduces the risk of part
problems whilst simultaneously
strengthening the part. An effective design
Uniform wall thickness should, therefore, a will use the plastic material in the optimum
key part of design, and parts should be proportions to maximize the results. Proper
gated into the thickest section to ensure an rib design also sidesteps molding problems,
even packout. Since material waste costs and therefore gives a faster molding cycle
money, this should be the aim of all with less quality control issues.
manufacturers, and it also cuts down on
quality issues further down the line. Plastic
parts will need to be cored out to the
maximum to utilize material better, as well
as minimizing the risk of part stress and
warpage. If extra strength or rigidity are
needed, then ribs are to be used.

⚫ Ribs for Strength and Quality

Where added part strength and rigidity are
necessary, then thinner rib sections make for

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It is also important to note that color
variation will occur in thick and thin sections.
With a thicker section, the color will appear
more vibrant and intense. This is especially
noticeable when using translucent colors,
and with certain types of resins depending
on the section thickness.
⚫ Weld-Line Considerations
Wherever the material is required to flow
around an obstacle, hole, boss, or cutout, a
weld-line will be formed, at the point that
multiple melt flows meet. If this weld-line
forms at a high stress point, then this may
present a big problem to the integrity of the
part.
Designers will need to make a note of high-
stress areas on the part, allowing the mold
designer to select the best gate location for
the part carefully. The issue is often only
noticed when part failure occurs, but
through careful planning of cavity layout
and gate location, it can usually be averted.
So long as potential weld-line issues are
known in advance, then there are several
ways that those issues can be minimized.
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Shifting the gate location, or working to
minimize the weld-line effect at these
obstructions are both valid options. Another
option is multiple gating, which will naturally
change the point at which the melt fronts
meet, and the weld-line is formed.
One way to strengthen weld-lines at the
very edge of a part is to use flow tabs, which
will be removed later in the process. These
tabs are typically used at the points where
weld-lines form, to help the melt fronts to
flow together smoothly. To use them,
though, the mold cavity at this point needs
to be suitably vented, or the air in the cavity
will prevent a smooth meeting.
Excess air could slow down the melt fronts,
and cause bubbles to form. Should the air
not be vented fast enough, then it could well
cool the melt fronts so that they don’t bond
properly, creating a significantly weakened
melt-front. To solve this issue, extra
localized heating is often used on weld-lines
to ensure the melt fronts come together
nicely.
Weld-lines should be avoided in parts that
require holes, and there are a range of
methods to do this- especially if the lines
occur at high-stress points. The holes may
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be marked for drilling later in a secondary
operation. If countersunk bind holes are
needed, lA of the section thickness should
be retained. This will allow the material flow
to minimize the weld-line formation
opposite the hole. Where blind holes are
concerned, the minimum thickness of the
bottom should be at least ]/6 diameter. With
reinforced materials, the part’s weld-line
strength can be calculated by using the
parent resin，s strength.
The reason for this is that reinforcements
such as glass fibers will not flow over the
weld-line to link with the opposing melt
front. Even when using an external flow tab,
reinforcement interflow is unlikely until the
fronts are suitably far away from any
obstruction. In the case of some part
designs, the weld-lines may well be highly
visible. For instance, using colors or
reinforced materials means noticeable
surface variations will occur as the knit line.
To increase weld-line strength, the melt
temperature of the resin may be raised, or
the mold itself heated. There are usually
more issues with weld-line strength when
using amorphous resins since they have a
lower softening temperature and higher
melt viscosity. Crystalline resins，which have
a sharper melting point ， may cool and
freeze off faster, leading to a weak weld-line
joint. Using flow tabs with sufficient venting，
increased melt temperature, localized cavity
heating, and hotter mold temperatures can
limit these weld-line effects, and thereby
improve joint strength.
⚫ Bosses
Bosses act as the assembly point for mating
parts. As such, they will need to be designed
with a good strength of attachment in mind,
but at the same time, not cause any
problems with the part’s surface or
appearance. To help prevent the latter, it’s a
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good idea to situate bosses behind the
nonvisible surface of a part. Should bosses
or ribs not be designed correctly, then this
can lead to weld-line, void, and sink
problems in the parts. Whether the boss is
open or blind, they will still require radii, and
need to have a uniform wall thickness
throughout. To ensure this, without
compromising on strength, the boss may be
strengthened and supported through
additional ribs.
The final dimensions of the boss will largely
be determined by the type of fastener used
within it. Material suppliers will be able to
recommend the optimum boss design for
their own respective material. This design is
based around the insert or screw type
required for the attachment, as well as its
necessary holding strength.
There are, however, other methods of boss
design. These require through holes in order
to cut surface effects, while also increasing
the strength of the boss and weld-line. This
technique is quite similar to the one used for
blind holes, allowing the material to flow
around and through the bottom section of
the boss. The base of the boss can then be
drilled out in an additional operation, which
will complete the part’s requirements. That
being said, it is essential that part designers
keep the molding, assembly function, and
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appearance in mind when they design these
parts.
If blind holes are to be molded in a part,
then the core pins which make up these
holes require rigid support. This is
particularly important with core pins where
the length-to-diameter ratio is more than
five. Core pins have to be tough and stiff in
order to not shift or bend under the high
injection pressure and speed at the point
where polymer is injected. Should the given
pin length-to-diameter be exceeded, then it
may be necessary to use a stepped core pin
design. Cooling will also need to be factored
in, since these types of core pins become
incredibly hot during the molding process.
With holes in a side wall, retractable core
pins may be used, or alternatively a split tool
(but only if the side wall can be tapered or
sloped to allow for this).
⚫ Threads
Either external or internal configurations
may be used to create threaded plastic parts.
Usually, the external thread will be created
by finding the parting line on the center line
of the thread. Where this is impossible, or if
the threaded part is in the mold operation
direction, then an unscrewing, thread-
forming device, or cam-operated side cores,
will need to be used for the mold.
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On the other hand, internal threads will
require an unscrewing device or collapsing
core. They can be stripped from the mold,
but only when the threads are well-rounded,
and their depth and number of undercuts
are kept to a minimum. Should one choose
the unscrewing approach, then the
individual part in the mold should be
indexed, so that it doesn’t rotate within the
cavity while the core is removed.
To strip threaded parts, the thread will need
to be formed with adequate radii. Should
sharp thread forms be used, then they could
well split upon stripping or become
impossible to remove from the core.
With parts that need to be stripped (such as
in an internally threaded boss), then the
cavity steel will first need to be removed
from the external diameter of the boss.
That way, the boss can expand when the
core is stripped. Both boss and part will need
to be adequately supported throughout the
stripping action, to prevent the part from
warping. The boss must be stiff and strong
enough to avoid collapsing or fracturing.
Threaded parts which have a diameter-to-
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wall thickness ratio of at least 20:1 must be
ejectable should the resin have the
necessary elongation to be ejected off the
core pin.
It is also possible to strip some glass
reinforced resins from a mold, but only
where the part temperature is high enough,
and the per cent strain isn’t exceeded.
During the election cycle, hotter parts have
a greater amount of allowable material
strain. For instance, a 33% glass reinforced
nylon may be stripped from a 100-degree F
mold only if the strain is below 1% or a 200-
degree F mold below 2% strain. The material
supplier should be consulted to ensure the
right design is used for optimum ejection.
Molded-in threads must be terminated at a
minimum of 0.1 inches from their ends. This
is to cut down on material and part fretting
due to repeated assembly and disassembly,
and also stops compound sharp corners at
the ends of threads.
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⚫ Undercuts
Undercuts are a vital feature for plastic parts.
They are mostly used to form attachment
and assembly features, which will cut down
on part costs and assembly hardware time.
Parts which feature external and internal
undercuts may be formed in three basic
ways- either collapsible and pulling cores,
split cavity molds, or being stripped from the
mold in the same way as screw threads.
Depending on the required degree of the
undercut, as well as the return angle which
forms beneath it, the majority of parts-
including reinforced materials in many
cases- may be stripped from a mold. It is
only when the return angle nears 0.5
degrees that an undercut is no longer
strippable. This sort of internal undercut can
be created through the use of two separate
core pins. Depending on the length-to-
diameter ratio of the pins, one end can nest
inside the mating pin to give additional
stability, or they can slot tightly together to
prevent any flashing at the pins’ meeting
point.
There are other nonstrippable undercuts
which use through-the-wall cores, or
alternatively an offset ejector pin system.
Due to the bending strength of the steel, this
undercut depth is limited to the thickness of
the plate or pin used to form it. What’s more,
the undercut also needs to be assisted by
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additional knock-out ejector systems. A
taper of at least 2 degrees needs to be
present on the undercut to ensure proper
release during operation, particularly when
molding resins that are highly shrinkable.
This will cut down on the bending stress on
the sliding core, as well as on the wear to the
core where it comes into contact with
mating metal parts.
It is also possible to strip undercuts in glass-
reinforced resins, but only if the design
doesn’t exceed the material’s elongation.
The allowable undercut percentage is about
1-2% for most materials. Using generous
radii and release angles will aid in a smooth
release, and cut stress concentrations during
the ejection.
When stripping undercuts, most of the parts
used are round. This is because rectangular
and closed-wall shapes are unstrippable.
Should a full-lipped undercut be used, then
the container would likely bow, and hence
lock up the part at its corners. This process
would usually destroy the part, or at least
stick in the cavity or on the core. For
undercuts at the center wall sections to
remain strippable, they will need to be kept
short, and the supporting cavity steel
removed first. This will allow the side wall of
the part to deflect upon ejection. The
undercut section of the stripped part will
therefore need to be capable of deflection
in order to be ejectable.
⚫ Inserts
Assembling parts use threaded inserts.
These will either be molded in to the part, or
attached on in a later operation- either as a
press fit, or inserted ultrasonically. Primarily,
they are used to greaten the assembly
holding force of parts, cut down on material
creep at assembly points, and to enable
access to areas that will need to be serviced.
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Inserts often cost a lot of money, and
depending on the part in question and how
they can installed, they can be either helpful
or harmful. As with bosses and ribs, they
should therefore only be used when
necessary. There are cheaper and easier
alternatives, such as molded-in snap and
press fits and screws, which may be a
superior alternative. There are four main
reasons why inserts are used:
1. For threads which will be under a
constant load or stress, or where
parts will be frequently
disassembled.
2. To give a close tolerance on male or
female threads.
3. For permanently attaching two parts
which are highly loaded- for
instance, a gear shaft and a pulley.
4. To allow an electrical current to flow
between the two parts.
If it has been determined that inserts are
required, then the next thing to think about
is whether one will use inserts which are
molded-in, or add them in a secondary
operation. For parts made up of high-
shrinkage material, where the exact
dimensional location must be very precise,
or if there is a risk of boss stress fractures,
then ultrasonic insertion is the preferred
approach. This is because it allows an exact
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insert location, and cuts down dramatically
on the stress on the boss.
On the other hand, the reasons for using
molded-in inserts are a bit more
complicated. While they are cheaper and
have the advantage of being permanent,
there are still factors which need to be
considered before they are chosen. The
following problems may occur when using
molded-in inserts:
1. Loading the inserts by hand will
necessarily disrupt the molding
cycle. While the use of robots will
prolong the cycle, it will at least even
it out.
2. Inserts can become unattached or
float, which will damage the mold.
3. Degreasing and preheating is
required to cut down on boss stress.
4. Salvaging rejected parts with inserts
is much more expensive.
5. In order to avoid flash in the
threaded areas, a tight shutoff is
needed at the insert mold face.
The weld-line strength around the inserts is
also something that needs to be considered.
Boss inserts for molding should be designed
around the existing criteria for keeping
weld-line formation to a minimum and
avoiding lines that are too visible. When
using reinforced resins, the weld-line
strength might only be 60% of the
unreinforced resin due to a weak bonding
along the knit line. However, the boss
strength at the mold line can be boosted by
putting a rib at the weld-line junction. By
using multiple ribs, one can add additional
rigidity and strength. The following factors
should also be considered when using
inserts:
1. Avoid sharp corners, and include an
undercut to increase pullout
strength.
2. The insert should protrude at least
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0.6 inches into the mold cavity to
give a superior seal off and prevent
resin contamination to threads.
3. Below the insert, the thickness
should be at least 1/6 of the insert
diameter to add weld-line strength.
4. Toughened grades of materials,
with higher elongations, will lower
the risk of boss stress cracking.
5. Inserts must be clean and free of oil
or grease.
6. With high-shrinkage resins, the
inserts should be preheated to
lower part shrinkage and improve
weld-line strength.
7. A thorough end-use test should be
carried out, it could test the part
through temperature ranges and
stress and vibration loading, to
check for any problems with the
selected assembly method.
⚫ Tolerances:
A high degree of accuracy in molded parts
is expensive to achieve. On small tolerances
as close as -0.002 in. On large pieces,
tolerances of about 土 0.001 to 0.002 in. per
in. are obtainable. Tolerances closer than
actually mandatory should not be specified;
as specified accuracy increases, cost
increases disproportionately.
⚫ General principle
Though it is difficult to generalize about
design factors for injection, compression
and transfer moldings, the following design
rules should be considered:
1. Use sufficient draft on long thin
shapes to permit their withdrawal
from the mold.
2. Minimize coring. When cores are
used they should be easy to
withdraw.
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3. Avoid internal and external

undercuts; they make removal of
parts difficult and require
considerably more expensive
molds.
4. Provide ample fillets on inside
comers, and avoid sharp external
edges and comers except at the
parting line of the die.
5. Avoid large flat areas. Dappling or
otherwise breaking up the surface
is recommended.
6. Keep tolerances as liberal as
possible. Excessively close
tolerances add to cost because of
increased die costs and high
rejection rate.
7. Avoid abrupt changes in wall
thickness.
8. Locate parting lines so that flash
can be removed easily without
marring surrounding areas.
9. Locate holes for easy coring.
10. Use ribs to achieve desired
strength and stiffness. Ribs permit
materials savings by reducing
section thickness.
11. Use inserts for threaded holes
where high stresses are
anticipated or where considerable
wear is to be encountered. Round
inserts are preferred.

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